WO2005108890A2 - Natural gas liquefaction - Google Patents

Natural gas liquefaction Download PDF

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Publication number
WO2005108890A2
WO2005108890A2 PCT/US2005/014814 US2005014814W WO2005108890A2 WO 2005108890 A2 WO2005108890 A2 WO 2005108890A2 US 2005014814 W US2005014814 W US 2005014814W WO 2005108890 A2 WO2005108890 A2 WO 2005108890A2
Authority
WO
WIPO (PCT)
Prior art keywords
sfream
stream
distillation column
receive
components
Prior art date
Application number
PCT/US2005/014814
Other languages
English (en)
French (fr)
Other versions
WO2005108890A3 (en
Inventor
John D. Wilkinson
Joe T. Lynch
Hank M. Hudson
Kyle T. Cuellar
Original Assignee
Ortloff Engineers, Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to NZ550149A priority Critical patent/NZ550149A/en
Priority to CN2005800141367A priority patent/CN101006313B/zh
Priority to JP2007511444A priority patent/JP2007536404A/ja
Priority to EA200602027A priority patent/EA011919B1/ru
Application filed by Ortloff Engineers, Ltd. filed Critical Ortloff Engineers, Ltd.
Priority to MXPA06012772A priority patent/MXPA06012772A/es
Priority to CA2562907A priority patent/CA2562907C/en
Priority to BRPI0510698-2A priority patent/BRPI0510698A/pt
Priority to KR1020067025531A priority patent/KR101273717B1/ko
Priority to EP05741264A priority patent/EP1745254A4/en
Priority to AU2005241455A priority patent/AU2005241455B2/en
Publication of WO2005108890A2 publication Critical patent/WO2005108890A2/en
Priority to EGNA2006000990 priority patent/EG25478A/xx
Priority to NO20065085A priority patent/NO20065085L/no
Publication of WO2005108890A3 publication Critical patent/WO2005108890A3/en
Priority to HK07111571.7A priority patent/HK1106283A1/xx

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0211—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle
    • F25J1/0214—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
    • F25J1/0215—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle with one SCR cycle
    • F25J1/0216—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle with one SCR cycle using a C3 pre-cooling cycle
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
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    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022—Hydrocarbons, e.g. natural gas
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    • F25J1/00—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/003—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production
    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
    • F25J1/0035—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration" by gas expansion with extraction of work
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    • F25J1/0032—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using the feed stream itself or separated fractions from it, i.e. "internal refrigeration"
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    • F25J1/0057—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the kind of cold generation within the liquefaction unit for compensating heat leaks and liquid production using an "external" refrigerant stream in a closed vapor compression cycle by vaporising a liquid refrigerant stream after expansion of the liquid refrigerant stream with extraction of work
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    • F25J1/02—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
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    • F25J1/0205—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a single-component refrigerant [SCR] fluid in a closed vapor compression cycle as a dual level SCR refrigeration cascade
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    • F25J1/0214—Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process using a multi-component refrigerant [MCR] fluid in a closed vapor compression cycle as a dual level refrigeration cascade with at least one MCR cycle
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    • F25J3/0204—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream characterised by the feed stream
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    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/08—Cold compressor, i.e. suction of the gas at cryogenic temperature and generally without afterstage-cooler
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/20—Integrated compressor and process expander; Gear box arrangement; Multiple compressors on a common shaft
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2230/00—Processes or apparatus involving steps for increasing the pressure of gaseous process streams
    • F25J2230/60—Processes or apparatus involving steps for increasing the pressure of gaseous process streams the fluid being hydrocarbons or a mixture of hydrocarbons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2240/00—Processes or apparatus involving steps for expanding of process streams
    • F25J2240/02—Expansion of a process fluid in a work-extracting turbine (i.e. isentropic expansion), e.g. of the feed stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2240/00—Processes or apparatus involving steps for expanding of process streams
    • F25J2240/30—Dynamic liquid or hydraulic expansion with extraction of work, e.g. single phase or two-phase turbine
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00—Refrigeration techniques used
    • F25J2270/02—Internal refrigeration with liquid vaporising loop
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00—Refrigeration techniques used
    • F25J2270/12—External refrigeration with liquid vaporising loop
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00—Refrigeration techniques used
    • F25J2270/60—Closed external refrigeration cycle with single component refrigerant [SCR], e.g. C1-, C2- or C3-hydrocarbons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2270/00—Refrigeration techniques used
    • F25J2270/66—Closed external refrigeration cycle with multi component refrigerant [MCR], e.g. mixture of hydrocarbons
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2290/00—Other details not covered by groups F25J2200/00 - F25J2280/00
    • F25J2290/40—Vertical layout or arrangement of cold equipments within in the cold box, e.g. columns, condensers, heat exchangers etc.

Definitions

  • This invention relates to a process for processing natural gas or other methane-rich gas streams to produce a liqueJfied natural gas (LNG) stream that has a high methane purity and a liquid stream containing predominantly hydrocarbons heavier than methane.
  • LNG liqueJfied natural gas
  • Natural gas is typically recovered from wells drilled into underground reservoirs.
  • methane usually has a major proportion of methane, i.e., methane comprises at least 50 mole percent of the gas.
  • the natural gas also contains relatively lesser amounts of heavier hydrocarbons such as ethane, propane, butanes, pentanes and the like, as well as water, hydrogen, nitrogen, carbon dioxide, and other gases.
  • ethane propane, butanes, pentanes and the like
  • water, hydrogen, nitrogen, carbon dioxide, and other gases are relatively lesser amounts of heavier hydrocarbons.
  • the present invention is generally concerned with the liquefaction of natural gas while producing as a co-product a liquid stream consisting primarily of hydrocarbons heavier than methane, such as natural gas liquids (NGL) composed of ethane, propane, butanes, and heavier hydrocarbon components, liquefied petroleum gas (LPG) composed of propane, butanes, and heavier hydrocarbon components, or condensate composed of butanes and heavier hydrocarbon components.
  • NNL natural gas liquids
  • LPG liquefied petroleum gas
  • Producing the co-product liquid stream has two important benefits: the LNG produced has a high methane purity, and the co-product liquid is a valuable product that may be used for many other purposes.
  • a typical analysis of a natural gas stream to be processed in accordance with this invention would be, in approximate mole percent, 84.2% methane, 7.9% ethane and other C components, 4.9% propane and other C 3 components, 1.0% iso-butane, 1.1% normal butane, 0.8% pentanes plus, with the balance made up of nitrogen and carbon dioxide. Sulfur containing gases are also sometimes present.
  • Multi-component refrigeration employs heat exchange of the natural gas with one or more refrigerant fluids composed of several refrigerant components in lieu of multiple single-component refrigerants. Expansion of the natural gas can be accomplished both isenthalpically (using Joule-Thomson expansion, for instance) and isentropically (using a work-expansion turbine, for instance).
  • FIG. 1 is a flow diagram of a natural gas liquefaction plant adapted for co-production of NGL in accordance with the present invention
  • FIG. 2 is a pressure-enthalpy phase diagram for methane used to illustrate the advantages of the present invention over prior art processes
  • FIGS. 3, 4, 5, 6, 7, and 8 are flow diagrams of alternative natural gas liquefaction plants adapted for co-production of a liquid stream in accordance with the present invention.
  • inlet gas enters the plant at 90°F [32°G] and 1285 psia [8,860 kPa(a)] as stream 31. If the inlet gas contains a concentration of carbon dioxide and/or sulfur compounds which would prevent the product streams from meeting specifications, these compounds are removed by appropriate pretreatment of the feed gas (not illustrated). In addition, the feed stream is usually dehydrated to prevent hydrate (ice) formation under cryogenic conditions.
  • the feed stream 31 is cooled in heat exchanger 10 by heat exchange with refrigerant streams and flashed separator liquids at -44°F [-42°C] (stream 39a). Note that in all cases heat exchanger 10 is representative of either a multitude of individual heat exchangers or a single multi-pass heat exchanger, or any combination thereof.
  • the decision as to whether to use more than one heat exchanger for the indicated cooling services will depend on a number of factors including, but not limited to, inlet gas flow rate, heat exchanger size, stream temperatures, etc.
  • the cooled stream 31a enters separator 11 at 0°F [-18°C] and 1278 psia [8,812 kPa(a)] where the vapor (stream 32) is separated from the condensed liquid (stream 33).
  • the vapor (stream 32) from separator 11 is divided into two streams, 34 and 36, with stream 34 containing about 15% of the total vapor. Some circumstances may-favor combining stream 34 with some portion of the condensed liquid (stream 38) to form combined stream 35, but in this simulation there is no flow in stream 38.
  • Stream 35 passes througliheat exchanger 13 in heat exchange relation with refrigerant stream 71e and liquid distillation stream 40, resulting in cooling and substantial condensation of stream 35a.
  • the substantially condensed stream 35a at -109°F [-78°CJ is then flash expanded through an appropriate expansion device, such as expansion valve 14, to the operating pressure (approximately 465 psia [3,206 kPa(a)]) of fractionation tower 19. During expansion a portion of the stream is vaporized, resulting in cooling of the total stream.
  • the expanded stream 35b leaving expansion valve 14 reaches a temperature of -125°F [-87°C] and is then supplied at an upper mid-point feed position in absorbing section 19a of fractionation tower 19.
  • the remaining 85% of the vapor from separator 11 enters a work expansion machine 15 in which mechanical t energy is extracted from this portion of the high pressure feed.
  • the machine 15 expands the vapor substantially isentropically to the tower operating pressure, with the work expansion cooling the expanded stream 36a to a temperature of approximately -76°F [-60°C].
  • the typical commercially available expanders are capable of recovering on the order of 80-85% of the work theoretically available in an ideal isentropic expansion.
  • the work recovered is often used to drive a centrifugal compressor (such as item 16) that can be used to re-compress the tower overhead gas (stream 49), for example.
  • the expanded and partially condensed stream 36a is supplied as feed to absorbing section 19a in distillation column 19 at a lower mid-column feed point.
  • Stream 39, the remaining portion of the separator liquid (stream 33) is flash expanded to slightly above the operating pressure of demethanizer 19 by expansion valve 12, cooling stream 39 to -44°F [-42°C] (stream 39a) before it provides cooling to the incoming feed gas as described earlier.
  • Stream 39b, now at 85°F [29°C] then enters stripping section 19b in demethanizer 19 at a second lower mid-column feed point.
  • the demethanizer in fractionation tower 19 is a conventional distillation column containing a plurality of vertically spaced trays, one or more packed beds, or some combination of trays and packing.
  • the fractionation tower may consist of two sections.
  • the upper absorbing (rectification) section 19a contains the trays and/or packing to provide the necessary contact between the vapor portion of the expanded stream 36a rising upward and cold liquid falling downward to condense and absorb the ethane, propane, and heavier components; and the lower, stripping section 19b contains the trays and/or packing to provide the necessary contact between the liquids falling downward and the vapors rising upward.
  • the stripping section also includes one or more reboilers (such as reboiler 20) which heat and vaporize a portion of the liquids flowing down the column to provide the stripping vapors which flow up the column to strip the Hquid product, stream 41, of methane and lighter components.
  • the liquid product stream 41 exits the bottom of demethanizer 19 at 150°F [66°C], based on a typical specification of a methane to ethane ratio of 0.020:1 on a molar basis in the bottom product.
  • the overhead distillation vapor stream 37 containing predominantly methane and lighter components, leaves the top of demethanizer 19 at -108°F [-78°C].
  • a portion of the distillation vapor (stream 42) is withdrawn from the upper region of stripping section 19b.
  • This stream is cooled from -58°F [-50°C] to -109°F [-78°C] and partially condensed (stream 42a) in heat exchanger 13 by heat exchange with refrigerant stream 71e and liquid distillation stream 40.
  • the operating pressure in reflux separator 22 (461 psia [3,182 kPa(a)]) is maintained slightly below the operating pressure of demethanizer 19. This provides the driving force which causes distillation vapor stream 42 to flow through heat exchanger 13 and thence into the reflux separator 22 wherein the condensed liquid (stream 44) is separated from any uncondensed vapor (stream 43).
  • Stream 43 combines with the distillation vapor stream (stream 37) leaving the upper region of absorbing section 19a of demethanizer 19 to form cold residue gas stream 47 at -108°F [-78°C].
  • the condensed liquid (stream 44) is pumped to higher pressure by pump 23, whereupon stream 44a at -109°F [-78°C] is divided into two portions.
  • One portion, stream 45, is routed to the upper region of absorbing section 19a of demethanizer 19 to serve as the cold liquid that contacts the vapors rising upward through the absorbing section.
  • the other portion is supplied to the upper region of stripping section 19b of demethanizer 19 as reflux stream 46.
  • Liquid distillation stream 40 is withdrawn from a lower region of absorbing section 19a of demethanizer 19 and is routed to heat exchanger 13 where it is heated as it provides cooling of distillation vapor stream 42, combined stream 35, and refrigerant (stream 71a).
  • the liquid distillation stream is heated from -79°F [-62°C] to -20°F [-29°C], partially vaporizing stream 40a before it is supplied as a mid-column feed to stripping section 19b in demethanizer 19.
  • the cold residue gas (stream 47) is warmed to 94°F [34°C] in heat exchanger 24, and a portion (stream 48) is then withdrawn to serve as fuel gas for the plant.
  • the amount of fuel gas that must be withdrawn is largely determined by the fuel required for the engines and/or turbines driving the gas compressors in the plant, such as refrigerant compressors 64, 66, and 68 in this example.
  • the remainder of the warmed residue gas (stream 49) is compressed by compressor 16 driven by expansion machines 15, 61, and 63. After cooling to 100°F [38°C] in discharge cooler 25, stream 49b is further cooled to -93 °F [-69°C] (stream 49c) in heat exchanger 24 by cross exchange with cold residue gas stream 47.
  • Stream 49c then enters heat exchanger 60 and is further cooled by expanded refrigerant stream 71d to -256°F [-160°C] to condense and subcool it, whereupon it enters a work expansion machine 61 in which mechanical energy is extracted from the stream.
  • the machine 61 expands liquid stream 49d substantially isentropically from a pressure of about 638 psia [4,399 kPa(a)] to the LNG storage pressure (15.5 psia [107 kPa(a)]), slightly above atmospheric pressure.
  • the work expansion cools the expanded stream 49e to a temperature of approximately -257°F [-160°C], whereupon it is then directed to the LNG storage tank 62 which holds the LNG product (stream 50).
  • the working fluid for this refrigeration cycle is a mixture of hydrocarbons and nitrogen, with the composition of the mixture adjusted as needed to provide the required refrigerant temperature while condensing at a reasonable pressure using the available cooling medium.
  • condensing with cooling water has been assumed, so a refrigerant mixture composed of nitrogen, methane, ethane, propane, and heavier hydrocarbons is used in the simulation of the FIG. 1 process.
  • the composition of the stream in approximate mole percent, is 6.9% nitrogen, 40.8% methane, 37.8% ethane, and 8.2% propane, with the balance made up of heavier hydrocarbons.
  • the refrigerant stream 71 leaves discharge cooler 69 at 100°F [38°C] and 607 psia
  • the refrigerant is condensed and then subcooled to -256°F [-160°C] in heat exchanger 60 by expanded refrigerant stream 71 d.
  • the subcooled liquid sfream 71c enters a work expansion machine 63 in which mechanical energy is extracted from the stream as it is expanded substantially isentropically from a pressure of about 586 psia [4,040 kPa(a)] to about 34 psia [234 kPa(a)].
  • a portion of the stream is vaporized, resulting in cooling of the total stream to -262°F [-163°C] (sfream 71 d).
  • the expanded stream 71d then reenters heat exchangers 60, 13, and 10 where it provides cooling to stream 49c, stream 35, stream 42, and the refrigerant (streams 71, 71a, and 71b) as it is vaporized and superheated.
  • the superheated refrigerant vapor (stream 71 g) leaves heat exchanger 10 at 93 °F
  • each of the three compression stages (refrigerant compressors 64, 66, and 68) is driven by a supplemental power source and is followed by a cooler (discharge coolers 65, 67, and 69) to remove the heat of compression.
  • the compressed stream 71 from discharge cooler 69 returns to heat exchanger 10 to complete the cycle.
  • Specific power consumption required, which is the ratio of the total refrigeration compression power to the total liquid production rate.
  • Published information on the specific power consumption for prior art processes for producing LNG indicates a range of 0.168 HP-Hr/Lb [0.276 kW-Hr/kg] to 0.182 HP-Hr/Lb [0.300 kW-Hr/kg], which is believed to be based on an on-sfream factor of 340 days per year for the LNG production plant.
  • the specific power consumption for the FIG. 1 embodiment of the present invention is 0.139 HP-Hr/Lb [0.229 kW-Hr/kg], which gives an efficiency improvement of 21-31% over the prior art processes.
  • the first factor can be understood by examining the thermodynamics of the liquefaction process when applied to a high pressure gas stream such as that considered in this example. Since the primary constituent of this stream is methane, the thermodynamic properties of methane can be used for the purposes of comparing the liquefaction cycle employed in the prior art processes versus the cycle used in the present invention.
  • FIG. 2 contains a pressure-enthalpy phase diagram for methane.
  • the total amount of cooling required for the present invention (the sum of paths A-A 1 and A"-B') is less than the cooling required for the prior art processes (path A-B), reducing the refrigeration (and hence the refrigeration compression) required to liquefy the gas stream.
  • the second factor accounting for the improved efficiency of the present invention is the superior performance of hydrocarbon distillation systems at lower operating pressures.
  • the hydrocarbon removal step in most of the prior art processes is performed at high pressure, typically using a scrub column that employs a cold hydrocarbon liquid as the absorbent sfream to remove the heavier hydrocarbons from the incoming gas sfream.
  • Operating the scrub column at high pressure is not very efficient, as it results in the co-absorption of a significant fraction of the methane from the gas sfream, which must subsequently be stripped from the absorbent liquid and cooled to become part of the LNG product.
  • the hydrocarbon removal step is conducted at the intermediate pressure where the vapor-liquid equilibrium is much more favorable, resulting in very efficient recovery of the desired heavier hydrocarbons in the co-product liquid stream.
  • the present invention can be adapted to recover an NGL sfream containing a significantly higher fraction of the C 2 components present in the feed gas, to recover an LPG sfream containing only the C 3 and heavier components present in the feed gas, or to recover a condensate sfream containing only the C 4 and heavier components present in the feed gas, rather than producing an NGL co-product containing only a moderate fraction of the C 2 components as described earlier.
  • the present invention is particularly advantageous over the prior art processes when only partial recovery of the C 2 components in the feed gas is desired while capturing essentially all of the C 3 and heavier components, as the reflux stream 45 in the FIG. 1 embodiment allows maintaining very high C component recovery regardless of the C 2 component recovery level.
  • the absorbing (rectification) section of the demethanizer it is generally advantageous to design the absorbing (rectification) section of the demethanizer to contain multiple theoretical separation stages.
  • the benefits of the present invention can be achieved with as few as one theoretical stage, and it is believed that even the equivalent of a fractional theoretical stage may allow achieving these benefits. For instance, all or a part of the pumped condensed liquid (stream 44a) leaving reflux separator 22. and all or a part of the expanded substantially
  • FIG. 1 represents the preferred embodiment of the present invention for the processing conditions indicated.
  • FIGS. 3 through 8 depict alternative embodiments of the present invention that may be considered for a particular application.
  • the cooled feed stream 31a leaving heat exchanger 10 may not contain any liquid (because it is above its dewpoint, or because it is above its cricondenbar).
  • separator 11 shown in FIGS. 1 and 3 through 8 is not required, and the cooled feed stream can be divided into streams 34 and 36, which then can flow to heat exchange (stream 34) and to an appropriate expansion device (sfream 36), such as work expansion machine 15.
  • the distillation vapor stream 42 is partially condensed and the resulting condensate used to absorb valuable C 3 components and heavier components from the vapors rising through absorbing section 19a of demethanizer 19 (FIGS. 1 and 4 through 8) or absorber column 18 (FIG. 3).
  • the present invention is not limited to this embodiment. It may be advantageous, for instance, to treat only a portion of these vapors in this manner, or to use only a portion of the condensate as an absorbent, in cases where other design considerations indicate portions of the vapors or the condensate should bypass absorbing section 19a of demethanizer 19.
  • Some circumstances may favor total condensation, rather than partial condensation, of distillation stream 42 in heat exchanger 13. Other circumstances may favor that distillation stream 42 be a total vapor side draw from fractionation column 19 rather than a partial vapor side draw.
  • the high pressure liquid (sfream 33 in FIGS. 1 and 3 through 8) need not be expanded and fed to a mid-column feed point on the distillation column. Instead, all or a portion of it may be combined with the portion of the separator vapor (sfream 34) flowing to heat exchanger 13. (This is shown by the dashed stream 38 in FIGS. 1 and 3 through 8.) Any remaining portion of the liquid may be expanded through an appropriate expansion device, such as an expansion valve or expansion machine, and fed to a mid-column feed point on the distillation column (stream 39b in FIGS. 1 and 3 through 8). Sfream 39 in FIGS. 1 and 3 through 8 may also be used for inlet gas cooling or other heat exchange service before or after the expansion step prior to flowing to the demethanizer, similar to what is shown by the dashed stream 39a in FIGS. 1 and 3 through 8.
  • the splitting of the vapor feed may be accomplished in several ways. In the processes of FIGS. 1 and 3 through 8, the splitting of vapor occurs following cooling and separation of any liquids which may have been formed.
  • the high pressure gas may be split, however, prior to any cooling of the inlet gas or after the cooling of the gas and prior to any separation stages.
  • vapor splitting may be effected in a separator.
  • FIG. 3 depicts a fractionation tower constructed in two vessels, absorber column
  • fractionation tower 19 may be split into two portions.
  • One portion (sfream 42) is routed to heat exchanger 13 to generate reflux for absorber column 18 as described earlier. Any remaining portion (sfream 54) flows to the lower section of absorber column 18 to be contacted by expanded substantially condensed stream 35b and reflux liquid (stream 45).
  • Pump 26 is used to route the liquids (stream 51) from the bottom of absorber column 18 to the top of stripper, column 19 so that the two towers effectively function as one distillation system.
  • the decision whether to construct the fractionation tower as a single vessel (such as demethanizer 19 in FIGS. 1 and 4 through 8) or multiple vessels will depend on a number of factors such as plant size, the distance to fabrication facilities, etc.
  • fractionation tower 19 is constructed as two vessels, as shown by dashed stream 40 in FIG. 3.
  • the liquid (stream 51a) leaving pump 26 can be split into two portions, with one portion (sfream 40) used for heat exchange and then routed to a mid-column feed position on stripper column 19 (sfream 40a). Any remaining portion (stream 52) becomes the top feed to stripper column 19.
  • stream 49a leaving the compressor may flow directly to heat exchanger 24 as shown in FIG. 5, or flow directly to heat exchanger.60 as shown in FIG. 6.
  • a compressor driven by an external power source such as compressor 59 shown in FIG. 7, may be used in lieu of compressor 16.
  • Other circumstances may not justify any compression of the stream at all, so that the stream flows directly to heat exchanger 60 as shown in FIG.
  • heat exchanger 24 is not included to heat the sfream before the plant fuel gas (stream 48) is withdrawn, a supplemental heater 58 may be needed to warm the fuel gas before it is consumed, using a utility stream or another process stream to supply the necessary heat, as shown in FIGS. 6 through 8.
  • Choices such as these must generally be evaluated for each application, as factors such as gas composition, plant size, desired co-product sfream recovery level, and available equipment must all be considered.
  • the cooling of the inlet gas sfream and the feed stream to the LNG production section may be accomplished in many ways.
  • inlet gas sfream 31 is cooled and condensed by external refrigerant streams and flashed separator liquids.
  • the cold process streams could also be used to supply some of the cooling to the high pressure refrigerant (stream 71a).
  • any sfream at a temperature colder than the sfream(s) being cooled may be utilized. For instance, a side draw of vapor from fractionation tower 19 in FIGS. 1 and 4 through 8 or absorber column 18 in FIG. 3 could be withdrawn and used for cooling.
  • the supplemental external refrigeration that is supplied to the inlet gas sfream and to the feed sfream to the LNG production section may also be accomplished in many different ways.
  • boiling single-component refrigerant has been assumed for the high level external refrigeration and vaporizing multi-component refrigerant has been assumed for the low level external refrigeration, with the single-component refrigerant used to pre-cool the multi-component refrigerant sfream.
  • both the high level cooling and the low level cooling could be accomplished using single-component refrigerants with successively lower boiling points (i.e., "cascade refrigeration"), or one single-component refrigerant at successively lower evaporation pressures.
  • both the high level cooling and the low level cooling could be accomplished using multi-component refiigerant streams with their respective compositions adjusted to provide the necessary cooling temperatures.
  • the selection of the method for providing external refrigeration will depend on a number of factors including, but not limited to, feed gas composition and conditions, plant size, compressor driver size, heat exchanger size, ambient heat sink temperature, etc.
  • any combination of the methods for providing external refrigeration described above maybe employed in combination to achieve the desired feed sfream temperature(s).
  • Subcooling of the condensed liquid sfream leaving heat exchanger 60 reduces or eliminates the quantity of flash vapor that may be generated during expansion of the sfream to the operating pressure of LNG storage tank 62. This generally reduces the specific power consumption for producing the LNG by eliminating the need for flash gas compression. However, some circumstances may favor reducing the capital cost of the facility by reducing the size of heat exchanger 60 and using flash gas compression or other means to dispose of any flash gas that may be generated.
  • sfream expansion is depicted in particular expansion devices, alternative expansion means may be employed where appropriate. For example, conditions may warrant work expansion of the substantially condensed feed sfream (sfream 35a in FIGS. 1 and 3 through 8). Further, isenthalpic flash expansion may be used in lieu of work expansion for the subcooled liquid stream leaving heat exchanger 60 (stream 49d in FIGS. 1 and 3, sfream 49e in FIG. 4, stream 49c in FIG. 5, stream 49b in FIGS/6 and 7, and sfream 49a in FIG.
  • isenthalpic flash expansion may be used in lieu of work expansion for the subcooled high pressure refrigerant sfream leaving heat exchanger 60 (sfream 71c in FIGS. 1 and 3 through 8), with the resultant increase in the power consumption for compression of the refrigerant.
  • the relative amount of feed found in each branch of the split vapor feed will depend on several factors, including gas pressure, feed gas composition, the amount of heat which can economically be extracted from the feed, the hydrocarbon components to be recovered in the liquid co-product stream, and the quantity of horsepower available. More feed to the top of the column may increase recovery while decreasing power recovered from the expander thereby increasing the recompression horsepower requirements. Increasing feed lower in the column reduces the horsepower consumption but may also reduce product recovery.
  • the relative locations of the mid-column feeds may vary depending on inlet composition or other factors such as desired recovery levels and amount of liquid formed during inlet gas cooling.
  • two or more of the feed streams, or portions thereof may be combined depending on the relative temperatures and quantities of individual streams, and the combined sfream then fed to a mid-column feed position.

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PCT/US2005/014814 2004-05-04 2005-04-28 Natural gas liquefaction WO2005108890A2 (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
CA2562907A CA2562907C (en) 2004-05-04 2005-04-28 Natural gas liquefaction
JP2007511444A JP2007536404A (ja) 2004-05-04 2005-04-28 天然ガスの液化
EA200602027A EA011919B1 (ru) 2004-05-04 2005-04-28 Сжижение природного газа
KR1020067025531A KR101273717B1 (ko) 2004-05-04 2005-04-28 천연 가스 액화
MXPA06012772A MXPA06012772A (es) 2004-05-04 2005-04-28 Licuefaccion de gas natural.
CN2005800141367A CN101006313B (zh) 2004-05-04 2005-04-28 天然气液化方法
BRPI0510698-2A BRPI0510698A (pt) 2004-05-04 2005-04-28 liquefação de gás natural
NZ550149A NZ550149A (en) 2004-05-04 2005-04-28 Natural gas liquefaction using a more efficient process
EP05741264A EP1745254A4 (en) 2004-05-04 2005-04-28 NATURAL GAS LIQUIDS
AU2005241455A AU2005241455B2 (en) 2004-05-04 2005-04-28 Natural gas liquefaction
EGNA2006000990 EG25478A (en) 2004-05-04 2006-10-18 Natural gas liquefaction
NO20065085A NO20065085L (no) 2004-05-04 2006-11-03 Flytendegjoring av naturgass
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AU2005241455B2 (en) 2010-11-18
MXPA06012772A (es) 2007-02-14
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